Multi-Panel Tonneau Cover

ABSTRACT

A tonneau cover for a bed of a truck is provided. The tonneau cover includes several improvements including but not limited to a bulkhead panel that is secured to the truck. A first cover panel section pivotably attached to the bulkhead panel. A first intermediate panel section pivotably attached to the first cover panel section and a second panel section. A second intermediate panel section pivotably attached to the second cover panel section and a third panel section. The first cover panel section, the second cover panel section, and the third cover panel section fold to form a stack of cover panel sections which is pivoted upright onto the bulkhead panel which supports the stack of cover panel sections in an upright position. The second intermediate panel section sets upon the bulkhead panel when the stack of cover panel sections is pivoted upright onto the bulkhead panel.

RELATED APPLICATIONS

The present application relates to and claims priority to U.S.Provisional Application Nos. 62/875,172, entitled “Tonneau Cover,” filedon Jul. 17, 2019; and to U.S. Provisional Patent application, Ser. No.62/929,129, filed on Nov. 1, 2019 entitled “Mechanical Catch Assembly,”and to U.S. Provisional Application Ser. No. 62/928,448, filed on Oct.31, 2019 entitled “Tonneau Cover Multi-Piece Rail,” and to U.S.Provisional Application Ser. No. 62/929,189, filed on Nov. 1, 2019entitled “Tonneau Cover Panel Section Hinge Seals,” and to U.S.Provisional Application Ser. No. 62/928,606, filed on Oct. 31, 2019entitled “Tonneau Cover Panel Section Handle,” and to U.S. ProvisionalApplication Ser. No. 62/929,141, filed on Nov. 1, 2019 entitled “TonneauCover Wall Rail,” and to U.S. Provisional Application Ser. No.62/929,161, filed on Nov. 1, 2019 entitled “Bulkhead Panel Assembly,”and also claims priority to U.S. Provisional Application Ser. No.62/929,244, filed on Nov. 1, 2019, entitled “Four Panel Tonneau Cover.”The subject matter disclosed in that provisional application is herebyexpressly incorporated into the present application.

TECHNICAL FIELD AND SUMMARY

The present disclosure relates to trucks such as pickup trucks, andtruck beds used on pickup trucks and like vehicles and, in particular,truck bed covers also known as tonneau covers, used on such truck bedsthat include new features.

Tonneau covers are truck bed covers that provide a covering for a truckbed when used in combination with the truck's sidewalls and tailgate.Covering the bed of a pickup truck helps create a secure compartmentwhere items may be stored out of view when the tailgate is in an upwardand latched position. Embodiments of a tonneau cover may include thecover portion that is suspended over the truck bed between thesidewalls. Typically, a frame or rail assembly may be employed thatattaches to the opposing sidewalls to secure the cover onto the truck.

An illustrative embodiment of the present disclosure provides a tonneaucover for a bed of a truck. The tonneau cover comprises: first andsecond rails; each of the first and second rails are configured toattach to one of two opposed truck bed sidewalls; a bulkhead panel thatis secured to each of the first and second rails; a first cover panelsection pivotably attached to the bulkhead panel; a second cover panelsection; a first intermediate panel section pivotably attached to thefirst cover panel section and the second panel section; a third coverpanel section; a second intermediate panel section pivotably attached tothe second cover panel section and the third panel section; and a fourthcover panel section pivotally attached to the third cover panel section;wherein the first cover panel section, the second cover panel section,the third cover panel section, and the fourth cover panel section foldto form a stack of cover panel sections; wherein the stack of coverpanel sections is pivoted upright onto the bulkhead panel which supportsthe stack of cover panel sections in an upright position; wherein thestack of cover panel sections form a generally triangularly-shaped sideprofile such that a bottom portion of the generally triangularly-shapedside profile of the stack of cover panel sections is wider than a topportion of the generally triangularly-shaped side profile of the stackof cover panel sections; and wherein the second intermediate panelsection sets upon the bulkhead panel when the stack of cover panelsections is pivoted upright onto the bulkhead panel.

In the above and other embodiments, the tonneau cover may furthercomprise: the first intermediate panel section has a side profile widthless than a side profile width of the second intermediate panel section;the first intermediate panel section has a side profile width less thanor equal to a side profile width of the second intermediate panelsection; a first flexible hinge attaches the first cover panel sectionto the bulkhead panel, a second flexible hinge that attaches the firstintermediate panel section to the first cover panel section, a thirdflexible hinge that attaches the first intermediate panel section to thesecond panel section, a fourth flexible hinge that attaches the secondintermediate panel section to the second cover panel section, and afifth flexible hinge that attaches the second intermediate panel sectionto the third panel section; the first intermediate panel section has aside profile width that is not greater than a side profile width of thesecond intermediate panel section; at least one of the cover panelsections of the stack of cover panel sections has a side profile that ispositioned non-parallel with at least one of another cover panel sectionof the stack of cover panel sections; the stack of cover panel sectionsthat is pivoted upright onto the bulkhead panel which supports the stackof cover panel sections in an upright position is configured to notblock a center high mount stop lamp on the truck; the bulkhead panelincludes at least one tab, at least a portion of which is sized toengage at least a portion of the second intermediate panel section todetermine a location on the bulkhead panel that supports the stack ofcover panel sections in the upright position; the second intermediatepanel section includes at least one channel as the at least a portion ofthe second intermediate panel section to receive the at least a portionof the at least one tab; the at least one tab on the bulkhead panel is aplurality of tabs; and the at least one tab on the bulkhead panel hascharacteristics selected from the group consisting of at least one of adetent, friction fit, and fastener.

Another illustrative embodiment of the present disclosure provides atonneau cover for a bed of a truck. The tonneau cover comprises: abulkhead panel that is configured to secure to the truck; a plurality ofcover panel sections pivotably attached to each other; and anintermediate panel section pivotably attached to at least one of thecover panel sections of the plurality of cover panel sections; whereinthe plurality of cover panel sections fold to form a stack of coverpanel sections; wherein the stack of cover panel sections is pivotedupright onto the bulkhead panel which supports the stack of cover panelsections in an upright position; wherein the intermediate panel sectionsets upon the bulkhead panel when the stack of cover panel sections ispivoted upright onto the bulkhead panel; and wherein the bulkhead panelincludes at least one tab, at least a portion of which is sized toengage at least a portion of the second intermediate panel section todetermine a location on the bulkhead panel that supports the stack ofcover panel sections in an upright position.

In the above and other embodiments, the tonneau cover may furthercomprise: the second intermediate panel section includes at least onechannel as the at least a portion of the second intermediate panelsection to receive the at least a portion of the at least one tab; theat least one tab on the bulkhead panel is a plurality of tabs; the atleast one tab on the bulkhead panel has characteristics selected fromthe group consisting of at least one of a detent, friction fit, andfastener; and the stack of cover panel sections form a generallytriangularly-shaped side profile such that a bottom portion of thegenerally triangularly-shaped side profile of the stack of cover panelsections is wider than a top portion of the generallytriangularly-shaped side profile of the stack of cover panel sections.

Another illustrative embodiment of the present disclosure provides atonneau cover for a bed of a truck. The tonneau cover comprises: abulkhead panel that is secured to the truck; a first cover panel sectionpivotably attached to the bulkhead panel; a second cover panel section;a first intermediate panel section pivotably attached to the first coverpanel section and the second panel section; and a third cover panelsection; a second intermediate panel section pivotably attached to thesecond cover panel section and the third panel section; wherein thefirst cover panel section, the second cover panel section, and the thirdcover panel section fold to form a stack of cover panel sections;wherein the stack of cover panel sections is pivoted upright onto thebulkhead panel which supports the stack of cover panel sections in anupright position; wherein the first intermediate panel section has aside profile width less than a side profile width of the secondintermediate panel section; and wherein the stack of cover panelsections form a generally triangularly-shaped side profile such that abottom portion of the generally triangularly-shaped side profile of thestack of cover panel sections is wider than a top portion of thegenerally triangularly-shaped side profile of the stack of cover panelsections.

In the above and other embodiments, the tonneau cover may furthercomprise: at least one of the cover panel sections of the stack of coverpanel sections has a side profile that is positioned non-parallel withat least one other cover panel sections of the stack of cover panelsections; and the bulkhead panel includes at least one tab, at least aportion of which is sized to engage at least a portion of the secondintermediate panel section to determine a location on the bulkhead panelthat supports the stack of cover panel sections in the upright position.

Another illustrative embodiment of the present disclosure provides atonneau cover for a bed of a truck. The tonneau cover comprises: abulkhead panel that is secured to the truck; a first cover panel sectionpivotably attached to the bulkhead panel; a second cover panel section;a first intermediate panel section pivotably attached to the first coverpanel section and the second panel section; a third cover panel section;a second intermediate panel section pivotably attached to the secondcover panel section and the third panel section; wherein the first coverpanel section, the second cover panel section, and the third cover panelsection fold to form a stack of cover panel sections; wherein the stackof cover panel sections is pivoted upright onto the bulkhead panel whichsupports the stack of cover panel sections in an upright position;wherein the second intermediate panel section sets upon the bulkheadpanel when the stack of cover panel sections is pivoted upright onto thebulkhead panel; and wherein the first intermediate panel section has aside profile width less than or equal to a side profile width of thesecond intermediate panel section.

Additional features and advantages of the tonneau cover assembly willbecome apparent to those skilled in the art upon consideration of thefollowing detailed descriptions of carrying out the tonneau coverassembly as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The concepts described in the present disclosure are illustrated by wayof example and not by way of limitation in the accompanying figures. Forsimplicity, and clarity of illustration, elements illustrated in thefigures are not necessarily drawn to scale. For example, the dimensionsof some elements may be exaggerated relative to other elements forclarity. Further, where considered appropriate, reference labels may berepeated among the figures to indicate corresponding or analogouselements.

FIG. 1 is a rear perspective view of a pickup truck with an accompanyingtruck bed having tonneau cover lying over top;

FIG. 2 is another perspective view of the truck of FIG. 1 depicting thetonneau cover in a partially folded-up position;

FIG. 3 is another perspective view of the tonneau cover furtherfolded-up;

FIG. 4 is another perspective view of the truck with the tunneau coverfurther folded-up;

FIG. 5 is another perspective view of the truck with the tonneau coverfolded up into a stack set up right;

FIGS. 6A, 6B, 6C, 6D, and 6E are progression views of the tonneau coverassembly shown between fully closed and fully open positions;

FIG. 7 is a side isolated detail view of the tonneau cover with thecover panel sections folded and stacked onto a bulkhead panel;

FIG. 8; is a side detail view of portions of the tonneau cover;

FIG. 9 is an underside perspective view of a portion of the tonneaucover;

FIG. 10 is a perspective exploded view of the tonneau cover;

FIG. 11 is an exploded view of the tonneau cover in a folded, stacked,and upright position with respect to the bulkhead panel assembly;

FIG. 12 is a perspective isolated detail view of a portion of thetonneau cover;

FIG. 13 is a perspective isolated detail exploded view of a portion ofthe tonneau cover;

FIG. 14 is a perspective detail view of the tonneau cover in a folded,stack, and upright position on the bulkhead panel;

FIG. 15 is a perspective detail view of a portion of the tonneau coverfolded, stacked, and positioned upright on the bulkhead panel;

FIG. 16 shows comparative and views of a narrow intermediate panel and abase intermediate panel;

FIG. 17 is an isolated perspective view of a reinforced bulkhead panelassembly;

FIG. 18 is an exploded perspective view of the reinforced bulkhead panelassembly;

FIG. 19 is a side cross-sectional view of the reinforced bulkhead panelassembly;

FIG. 20 is a perspective cross-sectional view of a portion of thetonneau cover;

FIG. 21 is a side cross-sectional view of a portion of the tonneaucover;

FIG. 22 is a side detail view of a portion of the tonneau cover;

FIG. 23 is a perspective isolated detail exploded view of a portion ofthe tonneau cover;

FIG. 24 is a side detail view of a portion of the tonneau cover;

FIG. 25 is a perspective view of the tonneau cover shrouding a portionof the interior of the bed section of the truck;

FIG. 26 is another perspective view of the tonneau cover partiallyshrouding a portion of the truck bed of the truck;

FIG. 27 is a perspective detail view of the underside of a portion of acover section of the tonneau cover;

FIG. 28 is a across-sectional view of a side wall portion of the truckbed;

FIG. 29 is another across-sectional view of a portion of the side wallof the truck bed;

FIG. 30 is a cross-sectional exploded view of the side wall portion ofthe pickup truck and a portion of the tonneau cover and clamp;

FIG. 31 is a sectional view of the truck bed side wall with a clamp andrail;

FIG. 32 is an underside view of a portion of the tonneau cover, clamp,and rail;

FIG. 33 is another sectional view of the truck bed side wall, rail, andclamp;

FIG. 34 is an underside view of a portion of the tonneau cover, clamp,and rail;

FIG. 35 is a perspective view of the truck with the tonneau coverfolded, stacked, and positioned upright with respect to the truck bed;

FIG. 36 is a perspective detail view of an assembled split rail;

FIG. 37 is an exploded perspective detail view of the split rail andclamps;

FIGS. 38A, 38B, and 38C, are progression perspective detail viewsshowing the assembly of the split rails;

FIG. 39 is a prior art perspective view of a folded prior art tonneaucover and components related thereto, packaged in a prior art carton;

FIG. 40 is a perspective view of a folded tonneau cover according to thepresent disclosure along with components related thereto, packaged in acarton;

FIG. 41 is another perspective view of the tonneau cover and componentsrelated thereto, packaged in the carton;

FIG. 42 is a perspective exploded view of the tonneau cover andassociated components with illustrative packaging and the carton;

FIG. 43 is a perspective detail view of a mechanical catch assemblyportion of the tonneau cover;

FIG. 44 is another detail view of the mechanical catch assembly of thetonneau cover;

FIG. 45 is a perspective isolated detail view of the mechanical catchassembly coupled to the rail with a panel catch isolated from thetonneau cover;

FIG. 46 is an isolated view of the tonneau cover lying flat on the railand including the mechanical catch assembly;

FIG. 47 is a side elevational sectional and partial interior view of themechanical catch assembly; and

FIG. 48 is a side elevational partial cutaway interior view of themechanical catch assembly.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplification set out hereinillustrates embodiments of the tonneau cover assembly, and suchexemplification is not to be construed as limiting the scope of thetonneau cover assembly in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

The figures and descriptions provided herein may have been simplified toillustrate aspects that are relevant for a clear understanding of theherein described devices, systems, and methods, while eliminating, forthe purpose of clarity, other aspects that may be found in typicaldevices, systems, and methods. Those of ordinary skill may recognizethat other elements and/or operations may be desirable and/or necessaryto implement the devices, systems, and methods described herein. Becausesuch elements and operations are well known in the art, and because theydo not facilitate a better understanding of the present disclosure, adiscussion of such elements and operations may not be provided herein.However, the present disclosure is deemed to inherently include all suchelements, variations, and modifications to the described aspects thatwould be known to those of ordinary skill in the art.

An illustrative embodiment of the present disclosure provides a pickuptruck that includes a cab section located in front of a bed section. Thepickup truck comprises a tonneau cover that covers the bed section. Thetonneau cover includes a cover member that shrouds the truck bedunderneath. The cover member may be composed of one or more foldingsections that are hingedly attached to each other. The cover member mayalternatively be made of a soft material that is flexible enough to foldor roll between covered and uncovered positions with respect to thetruck bed underneath. To that end, the types of tonneau covers pertinentto this present disclosure are of the type that may be folded or rolledbetween covered and uncovered conditions with respect to the truck bed.

Multi Panel Tonneau Cover

An illustrative embodiment of the present disclosure also provides apickup truck that includes a multi sectioned tonneau cover.Illustratively, each of the sections are pivotable with respect to eachother and to a bulkhead panel. The cover sections may be supported onthe bulkhead panel in a vertical orientation when folded and stacked.Illustratively, a four panel folding tonneau cover has an advantage overa three panel cover, for example, in that each of the four coversections can be shorter, which means when stacked vertically on thebulkhead panel, the cover sections have less propensity to extend abovethe cab roof of the pickup truck. This translates into less likelihoodfor drag created by larger vertically oriented cover sections.

In a further illustrative embodiment, when the cover sections arestacked and oriented vertically, the cover sections are configured sothey do not all fold flat against each other to create a substantiallyrectangular side profile. Instead, the stacked panels form a generallytriangularly-shaped side profile. A disadvantage of having all of thecover sections folded flat against each other, thereby creating therectangularly-shaped side profile, is there is no inherent stability inthe stack when folded in this rectangular side profile configuration.Such a stack typically can only continue folding over center towards thetruck cab rear window because of this lack of stability.

Instead, the tonneau cover of the present disclosure includes at leastone intermediate panel so that when the panels are stacked andpositioned vertically on the bulkhead panel, the side profile width ofthe stack is greater at the bottom when compared at the top. At leastone of the cover sections is spaced apart from one or more of the othercover sections creating a space therebetween. Furthermore, that spacetherebetween has a greater distance towards the bottom of the coversection stack than at the top of the cover section stack. The effect ofthis is creating a triangularly-shaped side profile. By creating thiswider area at the bottom than at the top, the center of gravity is lowerand the vertically oriented stack of cover sections has betterstability. Prop rods can be used to maintain the cover sections in theirupright position while the truck is moving.

In a further embodiment, a positive placement assembly canillustratively be attached to the bulkhead panel and employed to engagethe wider bottom of the stacked cover sections. This assists theoperator in positioning the folded stack of cover sections at a desiredpredetermined location on the bulkhead panel.

A rear perspective view of a truck 2, with an accompanying truck bed 4comprising sidewalls 6 and 8, is shown in FIG. 1. This view also depictstailgate 10 and cab section 12 located opposite each other with truckbed 4 located therebetween. Illustratively, a tonneau cover 14 is shownshrouding interior 16 of truck bed 4 (see, also, FIG. 2). Tonneau cover14 is composed of a plurality of cover sections 18, 20, 22, and 24 thatare pivotably attached to each other as shown (see, also, FIGS. 2, 3,and 4). A bulkhead panel assembly 26 is secured to rails 28 and 30,which are positioned along the inner periphery of sidewalls 6 and 8,respectively. Illustratively, cover section 18 is pivotably attached tobulkhead panel assembly 26. It is appreciated that the tonneau cover 14shown herein is illustrative.

Another perspective view of truck 2 is shown in FIG. 2. In this view,tonneau cover 14 is depicted partially shrouding truck bed 4. Inparticular, cover section 18 is folded over cover section 20. Inaddition, cover section 20 is pivoted with respect to cover section 22.By folding at least one of the cover sections, interior 16 of truck bed4 becomes accessible. Latching assembly 32 is shown on panel 18. It iscontemplated that latching assembly 32 will engage rails 28 and 30 tolatch thereto when all of cover sections 18, 20, 22, and 24 of tonneaucover 14 are laid flat covering truck bed 4 and shrouding interior 16.Because latching assembly 32 is directed towards interior 16 of truckbed 4, such latches are concealed from the exterior of truck 2.

Another perspective view of truck 2 is shown in FIG. 3. Similar to theviews shown in FIGS. 1 and 2, truck 2 depicts tonneau cover 14 layingatop sidewalls 6 and 8 via rails 28 and 30 to shroud a portion ofinterior 16 of bed 4. This view, however, also shows cover sections 18and 20 of tonneau cover 14 folded over further than that shown in FIG. 2to further reveal interior 16 underneath. Also shown in this view is amechanical catch assembly 33 attached to rail 30 and bulkhead panelassembly 26.

A similar perspective view of truck 2, as shown in FIGS. 1, 2, and 3, isalso shown in FIG. 4. This view differs from FIGS. 1, 2, and 3 in thatcover sections 18 and 20 are folded over onto cover section 22.Illustratively, cover sections 18 and 20 have been pivoted in direction37 toward bulkhead panel assembly 26.

A similar perspective view of truck 2, as shown in FIGS. 1, 2, 3, and 4,is also shown in FIG. 5. This view differs from the others in that coversections 18, 20, 22, and 24 are folded over and stacked vertically ontobulkhead panel assembly 26. Prop rods 150 and 152 are both coupled tocover section 24 and onto rails 28 and 30, respectively. The prop rodsassist in keeping the stack of cover sections 18, 20, 22 and 24 uprightwhile truck 2 is moving. It is further appreciated from this view that,by virtue of the illustrative four foldable cover sections, the heightof the folded stack does not extend above the roof top 154 of cabsection 12. In addition, the folded stack does not cover the center highmount stop lamp (CHMSL) 155.

Perspective, isolated, progression views showing tonneau cover 14 onrails 28 and 30, with the tonneau cover being moved from a full closedposition to a full open position, is shown in FIGS. 6A, 6B, 6C, 6D, and6E. The view shown in FIG. 6A depicts tonneau cover 14 in its fullclosed position on rails 28 and 30. Here, as with the view shown in FIG.1, tonneau cover 14 completely shrouds interior 16 of truck bed 4. Assuch, cover sections 18, 20, 22, and 24 are unfolded and lay on rails 28to 30. Bulkhead panel assembly 26 is shown at the forward end of tonneaucover 14 adjacent cover section 24.

The view shown in FIG. 6B is the same as that of FIG. 6A, but with coversection 18 stacked on cover section 22 to begin opening tonneau cover14, similar to that shown in FIG. 2. The folding of tonneau cover 14continues in FIG. 6C where now both cover sections 18 and 20 are stackedonto cover section 22. By progressing with this stacked arrangement, itis appreciated that more of interior 16 of truck bed 4 will be exposedas further shown in FIGS. 4 and 5.

Further, stacking all of cover sections 18, 20, and 22 onto coversection 24 is shown in FIG. 6D. Lastly, as shown in FIG. 6E, the stackof cover sections 18, 20, 22, and 24 are pivoted upright onto bulkheadpanel assembly 26, which supports the stack in its upright position.Prop rods 150 and 152 attach to both cover section 24 and onto rails 28and 30, respectively, to maintain the stack of cover sections in thisupright position while the truck is moving. Further shown in this andthe other views are clamps 156 on both rails 28 and 30. Clamps 156 areconfigured to attach rails 28 and 30 to their adjacent sidewalls 6 and8, respectively.

A side isolated detail view of tonneau cover 14, located on bulkheadpanel assembly 26, which is attached to rail 28 (and 30, not shown inthis view), is shown in FIG. 7. This view demonstrates how the stackedcover sections 18, 20, 22, and 24, of tonneau cover 14, being pivotedupright onto bulkhead panel assembly 26, can maintain its stability. Incontrast to prior art designs that have fold-up cover sections so theyall lie flat against each other to form a rectangular side profile whenstacked upright, the stack configuration of tonneau cover 14 shown inFIG. 7 creates a triangularly-shaped side profile where the bottom orbase of the stack is wider than at the top. As shown in this view, theupright stack of cover sections of tonneau cover 14 include a baseintermediate panel 158, which is attached to cover sections 20 and 22,via flexible hinge members 160 and 162. Base intermediate panel 158 isthe support structure for cover sections 18, 20, 22, and 24 when seatedupright on bulkhead panel assembly 26. Opposite base intermediate panel158 is narrow intermediate panel 164, which is connected to coversections 22 and 24, via flexible hinge members 166 and 168, as shown.Because narrow intermediate panel 164 has a narrower width than baseintermediate panel 158 (see, also, FIG. 8), stacked cover sections 18,20, 22, and 24 form the triangularly-shaped side profile. Having a widerbase at the bottom and a narrower panel at the top means the uprightstack of tonneau cover 14 has a lower center of gravity and, thus, ismore stable when setting on bulkhead panel assembly 26. To that end, aspace 170 is formed between cover section 22 and cover section 18. Space170, as shown, is itself wider at the bottom, adjacent base intermediatepanel 158, and narrower at the top, adjacent narrow intermediate panel164.

A flexible hinge 172 is shown pivotally connecting cover sections 18 and20. Although not shown in this view, another such hinge (see hinge 182in FIG. 11) pivotally attaches cover section 24 to bulkhead panelassembly 26 to allow the stacked cover sections to pivot upright ontobulkhead panel assembly 26. Also shown in this view is a buckle receiver48. A positive placement tab 174 extends from buckle receiver 48 and issized to fit into an illustrative channel 176 formed in baseintermediate panel 158 as shown. It is appreciated that the bucklecomponent of buckle receiver 48 is optional. Positive placement tab 174may extend from another structure on bulkhead panel assembly 26, beintegrally formed with, or manifest itself in any other variety ofmanners that extends to fit into channel 176 of base intermediate panel158. As demonstrated, mating positive placement tab 174 with baseintermediate panel 158 helps stabilize the stack of cover sections 18,20, 22 and 24, when stacked and pivoted upright as shown in FIG. 7. Thisalso creates a consistent placement on bulkhead panel assembly 26. Italso helps keep the cover off of the exterior surface of bulkhead panelassembly 26 to prevent surface marring.

A side detail view of portions of tonneau cover 14 are shown in FIG. 8.This view depicts portions of cover sections 20, 22, and 24. Coversections 20 and 22, as previously discussed with respect to the view ofFIG. 7, are attached to base intermediate panel 158 via flexible hingemembers 160 and 162. Similarly, narrow intermediate panel 164 ispivotally coupled to cover sections 22 and 24 via flexible hinge members166 and 168. In order to obtain the triangularly-shaped side profile ofstacked tonneau cover 14 shown in FIG. 7, width 178 of base intermediatepanel 158 is wider than width 180 of narrow intermediate panel 164.

Comparative end views of narrow intermediate panel 164 and baseintermediate panel 158 is shown in FIG. 16. Because width 178 is widerthan width 180, base intermediate panel 158 can provide a stabilizingplatform for the stacked upright cover sections 18, 20, 22, and 24. Inan alternate illustrative embodiment, width 178 may be equal to width180. It is further notable from this view that the wider width 178 ofbase intermediate panel 158 joins cover sections 20 and 22 locatedtoward tailgate 10 of truck 2. In contrast, narrower width 180 of narrowintermediate panel 164, between cover sections 22 and 24, is locatedtowards the cab section 12 of truck 2.

An underside perspective view of a portion of tonneau cover 14 is shownin FIG. 9. Bulkhead panel assembly 26 is depicted with its bulkhead seal44 longitudinally extending the width of tonneau cover 14, andconfigured to engage space between the end of cover 14 and a front wallof truck bed 4, or the rear wall of cab section 12. In this illustrativeembodiment, cover section 24 may include a latching assembly 32 similarto a latching assembly 32 on cover section 18 on the other side oftonneau cover 14.

Illustratively, a perimeter seal 132 extends along the sides of tonneaucover 14 is shown to prevent rainwater or other contaminants fromseeping into truck bed 4 when tonneau cover 14 is laid flat as shown inFIG. 1. Extending longitudinally between cover sections 24 and 22 isnarrow intermediate panel 164 bounded by flexible hinge members 166 and168 as shown. Accordingly, narrow intermediate panel 164 is pivotablewith respect to cover sections 22 and 24, and vice versa.

Moving further along tonneau cover 14 toward tailgate 10, baseintermediate panel 158 is shown located between cover sections 20 and22. Flexible hinge members 160 and 162 pivotally attach baseintermediate panel 158 to cover section 22 and cover section 20,respectively. Again, it is appreciated from this view that the widerintermediate panel—base intermediate panel 158 having a width of 178—islocated further toward the tailgate 10 end of tonneau cover 14 ascompared to the narrower intermediate panel—narrow intermediate panel164 having width 180—being closer to cab section 12 end, on tonneaucover 14. Flexible hinge member 172 is longitudinally extending andpivotally coupling cover section 18 to cover section 20. Lastly, atailgate seal 184 is longitudinally extending along the width of coversection 18, illustratively adjacent latching assembly 32 as shown.

Perspective exploded views of tonneau cover 14 are shown in both FIGS.10 and 11. The view in FIG. 10 is tonneau cover 14 laid out in its flatcovering position. In contrast, the view in FIG. 11 shows tonneau cover14, albeit in exploded view, in its folded, stacked, and uprightposition, with respect to bulkhead panel assembly 26. As shown in bothviews, tonneau cover 14 includes bulkhead panel assembly 26, whichincludes a bulkhead seal 44, end caps 40 and 42, receivers 46 and 48,front frame 34, central panel 36, and hinge frame 38. Perimeter seals132 and 133 bound the lateral sides of tonneau cover 14 as shown. Hingemember 182 pivotally couples cover section 24 to bulkhead panel assembly26. Cover section 24 may illustratively include a frame member 186 thatengages part of hinge number 182 and panel 188. It is appreciated thatframe member 186, as well as the other frame members that are part ofcover sections 18, 20, 22, 24 may be made from a cast, extruded, orbent-formed metal material such as aluminum. End caps 190 and 192,illustratively, bound the sides of panel 188.

Another frame member 194, engages both panel 188 of cover section 24 andflexible hinge member 168, together. Narrow intermediate panel 164 ispivotally coupled to both flexible hinge members 166 and 168. Anotherframe member 196 couples to both flexible hinge member 166 and panel198, the latter being part of cover section 22. End caps 200 and 202 areshown bordering the side peripheries of panel 198 of cover section 22.Another frame member 204 engages both panel 198 and flexible hingemember 160. Based intermediate panel 158 is pivotally coupled to bothflexible hinge members 160 and 162. Another frame member 206 couples toboth flexible hinge member 162 and panel 208 as part of cover section20. Like the other cover sections, end caps 210 and 212 bound the sidesof panel 208 of cover section 20.

Bounding the opposite side of panel 208 from frame member 206 is framemember 214. Flexible hinge member 172 pivotally couples frame member 214from cover section 20 to frame member 216 of cover section 18. A panel218 is received in both frame member 216 and end frame panel 220. Endcaps 222 and 224 bound the peripheral sides of panel 218 of coversection 18, similar to the end caps of the other cover sections. Endcaps 226 and 228 can be attached to end frame panel 220 as shown, forexample, in FIG. 10. Tailgate seal 184 may be longitudinally extendingwith end frame panel 220 attaching thereto, to provide a sealingfunction between tonneau cover 14 and tailgate 10 of truck 2.

In an illustrative embodiment, end frame panel 220 may include a channel230 configured to receive a latching assembly 32 (see, also, FIG. 9).FIG. 11 also shows illustrative latch assemblies 32, which may beemployed in both cover sections 18 and 24. Alternatively, other latchingassemblies or catch assemblies may be employed as well. Also shown areprop rod mounts 232 and 234 which are attachable on cover section 24 andattachable to prop rods 150 and 152, respectively (see, also, FIG. 5).Clips 236 and 238 are shown and are also attachable to cover section 24.Clips 236 and 238 are configured to receive prop rods 150 and 152,respectfully, when same are not in use and are to be stored.

Perspective isolated detail and detail exploded views of a portion oftonneau cover 14 are shown and FIGS. 12 and 13. This portion of tonneaucover 14 is shown in the section between cover sections 22 and 24. Asshown, panel 188 fits into channel 240 of frame member 194. It isappreciated that the other frame members that bound cover sections 18,20, and 22 employ similar channel configurations to fit their panelstherein. Frame member 194 also includes a latch channel 242 configuredand sized to receive latching assembly 32. Also shown is prop rod mounts232 and 234. Fillers 244 and 248 fill any voids adjacent to theperiphery of the cover, between end caps such as end caps 222 and 224,or at hinge areas, adjacent perimeter seals such as perimeter seal 132.

A flexible hinge member 168 is shown pivotally coupling cover section 24to narrow intermediate panel 164. Additionally, it is appreciated thatother means of coupling the cover sections to the hinges may be employedand are contemplated to be within the scope of the disclosure herein.Flexible hinge member 168 is shown located between frame member 194 andnarrow intermediate panel 164. Frame member 196 also includes a channel250 which, similar to channel 240 as previously discussed, receivespanel 198 of cover section 22.

Another illustrative embodiment of the present disclosure includes apositive placement assembly that positions the folded, stacked, andpivoted cover sections 18, 20, 22, and 24 upright onto bulkhead panelassembly 26. Tonneau cover 14 has the ability to place the stacked coversections consistently at the predetermined location on bulkhead panelassembly 26, which assists in keeping tonneau cover 14 stable when coversections 18, 20, 22, and 24 are stacked in the upright position.

Perspective and perspective detail views of tonneau cover 14 thatincludes features of a positive placement assembly are shown in FIGS. 14and 15. Particularly, the features include a channel 176 longitudinallyformed on one side of base intermediate panel 158 (see, also, FIG. 7).Base intermediate panel 158 is the lowermost panel of the stacked coverand is what supports the rest of the upright stacked cover sections 18,20, 22, and 24. Base panel sections 252 into 254, located on each sideof channel 176, support the stack on the top surface of bulkhead panelassembly 26. Additionally, positive placement tab 174, extending upwardfrom bulkhead panel assembly 26, is fitted in channel 176 when coversections 18, 20, 22, and 24 are stacked upright. In the illustrativeembodiment, positive placement tab 174 extends from a buckle receiver 48attached to bulkhead panel assembly 26. Positive placement tab 174 mayalso alternatively be a separate structure extending from bulkhead panelassembly 26 or attached to a different structure, yet still fit intochannel 176 to help stabilize the stack of cover sections. Additionally,positive placement tab 174 may be a single tab, be multiple tabs, or alongitudinally extending tab along the width of bulkhead panel assembly26 depending on the need of tonneau cover 14. Still, further, positiveplacement tab 174 may have additional features on it, such as detents,friction fit surface, fastening means, etc., to assist in furthersupporting cover sections 18, 20, 22, and 24 onto bulkhead panelassembly 26.

Bulkhead Panel Assembly

A further illustrative embodiment of the present disclosure provides areinforced bulkhead panel for use as part of a tonneau cover. Thereinforced bulkhead panel extends from one truck bed sidewall to theother truck bed sidewall behind the cab section. The bulkhead panel issecured to the sidewalls and is hingedly attached to the remainingportion of the tonneau cover so the tonneau cover is able to pivot withrespect to the bulkhead panel. In addition, the reinforced bulkheadpanel is configured to support the weight of the remaining tonneau coverso, when folded to its stowed position, it can be stored atop thereinforced bulkhead panel which supports the cover's weight. Prop rods,straps, and other securement devices may be employed to assist couplingthe remaining portions of the tonneau cover onto the top of thereinforced bulkhead panel.

Another illustrative embodiment of the present disclosure provides areinforced bulkhead panel coupled to rails and/or sidewalls of the truckbed and suspended therebetween. The reinforced bulkhead panel includes acentral panel that is bounded by a front frame and a hinge frame fromfront to rear. The front frame is located adjacent the cab section ofthe pickup truck and includes a seal member that also spans between thesidewalls of the truck bed and extends to the cab section to form a sealbetween the cab section and the front frame. The hinge frame also spansbetween the sidewalls over the truck bed and is coupled to the centralpanel opposite the front frame. The hinge frame is configured tohingedly attach to the remainder of the tonneau cover.

Illustratively, the front frame, central panel, and hinge frame may allbe made from a metal material. Further, illustratively, the front andhinge frames and the central panel may be made from aluminum. And stillfurther illustratively, the front and hinge frames and central panel maybe each made from an extruded aluminum material. The front and hingeframes and central panel may have a generally uniform cross-sectionalshape along its longitudinal length.

An isolated perspective view of reinforced bulkhead panel assembly 26 isshown in FIG. 17. This view depicts a central panel 36 bounded by frontframe 34 and hinge frame 38. As shown, front frame 34 is located on whatwould be the front portion of tonneau cover 14, typically adjacent tothe end of truck bed 4, adjacent cab section 12, and indicated by frontF. Located opposite front frame 34, on central panel 36, and indicatedby rear R is hinge frame 38. Cover section 24 is hingedly attached tohinge frame 38, via a hinge 130 (see, also, FIG. 20). Also,illustratively shown are end caps 40 and 42 that bound the sides offront frame 34, central panel 36, and hinge frame 38. A bulkhead seal 44longitudinally extends about the length of front frame 34 to provide asealing functioned between it and either the end of truck bed 4 or cabsection 12. This illustrative embodiment of reinforced bulkhead panelassembly 26 shows optional buckle receivers 46 and 48. In someembodiments, buckle receivers 46 and 48 can be used to receive bucklesattached to one or more cover sections to secure same to the reinforcedbulkhead panel. This allows reinforced bulkhead panel assembly 26 tosupport the cover sections that may be seated on top of same.

An exploded perspective view of reinforced bulkhead panel assembly 26 isshown in FIG. 18. This view depicts the individual components that formreinforced bulkhead panel assembly 26. Illustratively, front frame 34includes a longitudinally extending channel 50 that fits over end 52 ofcentral panel 36. Bulkhead seal 44, also longitudinally extending asshown, fits onto front frame 34 (see, also, FIG. 19). Hinge frame 38, asshown, also includes a longitudinally extending channel 54 (see, also,FIG. 19) that receives end 56 of central panel 36. Central panel 36,front frame 34, and hinge frame 38 may be extruded components such asextruded aluminum that, when combined, reinforce each other sufficientto support the weight of stacked cover sections 18, 20, 22, and 24. Eachof endcaps 40 and 42 includes tabs 58 and 60, respectively, or otherlike structures configured to fit onto central panel 36. It isappreciated that tabs 58 and 60 may form a channel that receives andsecures onto central panel 36. Such securement may be enhanced byemploying fasteners, adhesive, or friction fit. Also shown are bucklereceivers 46 and 48 which may, illustratively, be attached to topsurface 62 of central panel 36 via fasteners 64.

A side cross-sectional view of reinforced bulkhead panel assembly 26 isshown in FIG. 19. Here, as shown, central panel 36, which is composed ofa top panel member 65 and a lower panel member 66, is located oppositetop panel member 65 with a space 68 located therebetween. To furtherassist separating top panel member 65 and lower panel member 66 arebrace members 70, 72, 74, and 76. Brace member 70 is located at end 52of central panel 36, whereas brace member 76 is located at end 56 ofcentral panel 36. Therebetween are spaced apart brace members 72 and 74extending between top panel member 65 and lower panel member 66 to formspace 68 there between. Again, central panel 36 may illustratively beextruded to form this cross-sectional profile.

Further shown herein is front frame 34, which includes front flange 78extending from central panel 36 to longitudinally extending channel 50.Underneath front flange 78 is a channel 80 that is furthered defined bytabs 82 and 84. It is appreciated that front flange 78, channel 80, andtabs 82 and 84 are longitudinally extending the length side-to-side offront frame 34. It is appreciated that front frame 34 may be extruded aswell, separately from central panel 36. Longitudinally extending channel50 is formed by flange members 86 and 88 via brace member 92. As shownherein, end 52 of central panel 36 fits into longitudinally extendingchannel 50. Illustrative longitudinally extending detents 94 and 96provide adhesive pockets to secure front frame 34 to central panel 36.In other embodiments, detents 94 and 96 may be used as friction fitgripping surfaces.

At rear R of central panel 36 (see, also FIG. 17), at end 56, hingeframe 38 is shown to include a hinge channel 98. Space 100, which islongitudinally extending and formed by flange members 102 and 104, arelongitudinally extending as well. Longitudinally extending channel 54 isshown formed by flange members 106 and 108, with brace member 110extending therebetween. End 56 of central panel 36 is depicted fittedinto longitudinally extending channel 54 in a similar manner to that ofend 52 fitted in longitudinally extending channel 50 of front frame 34.Detents 112 and 114 are formed on the inside of flange members 106 and108, respectively. This assists securing central panel 36 ontolongitudinally extending channel 54.

Further shown herein is bulkhead seal 44. It includes a longitudinallyextending first seal flange 116 that spans between the end of frontflange 78 of front frame 34 and cab section 12 (or other structuredepending on the make and model of the pickup truck) to provide a sealbetween the ends of tonneau cover 14 and truck bed 4. A secondary sealflange 118 is spaced apart from first seal flange 116 and islongitudinally extending the length of bulkhead seal 44. Secondary sealflange 118 may serve as a secondary flange. Both first and second sealflanges extend from a base seal member 120 located underneath frontflange 78 as illustratively shown. Opposite first seal flange 116 issecurement seal 122, which is sized and fitted into channel 80 of frontframe 34. This secures bulkhead seal 44 to front frame 34. Also shown inthis view is buckle receiver 46 located on top surface 62 and secured tocentral panel 36 via fasteners 64 as illustratively shown.

A perspective cross-sectional view of tonneau cover 14, includingreinforced bulkhead panel assembly 26 secured to rail 28, is shown inFIG. 20. In this view, a tie-down clamp assembly 124 is shown securingto central panel 36 and cover section 24. Tie-down clamp assembly 124includes a tie-down block clamp assembly 129 and a tie-down tether 134.Further details of tie down clamp assembly 124, tie-down block clampassembly 129, and tie-down tether 134 are described in U.S. patentapplication Ser. No. 16/593,049, entitled Tonneau Cover Tie-DownAssembly, filed Oct. 4, 2019, the disclosure of which is incorporatedherein by reference in its entirety.

As shown on the underside of lower panel member 66 is a clamp slot 126formed therein to receive an illustrative bolt head 128 or other likestructure from tie-down block clamp assembly 129, to secure reinforcedbulkhead panel 26 to rail 28. Although not shown herein, another clampslot is formed in lower panel member 66 adjacent rail 30 so another tiedown clamp assembly may attach the other side of reinforced bulkheadpanel assembly 26 to rail 30. The skilled artisan upon reading thepresent disclosure will appreciate that this additional clamp slotlocated adjacent rail 30, in combination with the shown tie down clampassembly 124, secures reinforced bulkhead panel assembly 26 to rail 28and, thus, fixes reinforced bulkhead panel assembly 26 to sidewalls 6and 8 of truck bed 4. This keeps reinforced bulkhead panel assembly 26stationary with respect to sidewalls 6 and 8, as well as to coversections 18, 20, 22, and 24 of the present tonneau cover 14, or to othertonneau cover designs that may be attached to reinforced bulkhead panelassembly 26. Also shown are flange members 86 and 108 of front frame 34and hinge frame 38, respectively, supporting central panel 36.

This view further illustrates how front frame 34 longitudinally couplesto central panel 36 via end 52 fitted into longitudinally extendingchannel 50. Also, bulkhead seal 44, with first seal flange 116 andsecondary seal flange 118, also longitudinally extends the length ofreinforced bulkhead panel assembly 26. Similarly, end 56 of centralpanel 36 is shown fitted into longitudinally extending channel 54 ofhinge frame 38 along the longitudinal length of bulkhead panel assembly26. A hinge 130 may be fitted into space 100 of hinge frame 38 toconnect same to cover section 24. This allows cover section 24 to bepivotally coupled to reinforced bulkhead panel assembly 26.

Further shown in this view is an illustrative perimeter seal 132, whichfits over reinforced bulkhead panel assembly 26 and rail 28. This viewalso shows end cap 40 illustratively positioned over rail 28.

A side cross-sectional view of a portion of tonneau cover 14 is shown inFIG. 21. This view depicts, among other features, a depending tab 127that prevents bolt head 128 from moving upwardly and disengaging thecarriage bolt's square shaft 139 from clamp slot 126. Tab 127 help keepbolt head 128 from rotating as the flower nut 137 is tightened. Furtherdisclosure of tie-down tether 134 and associated components may be foundin the Tonneau Cover Tie-Down Assembly Patent Application previouslyincorporated herein by reference.

Panel Section Hinge Seals

Another illustrative embodiment of the present disclosure focuses on anaspect of water management with regard to the hinge portions of thetonneau cover. Because tonneau covers spend the majority of their timein an outside environment, there is an expectation that water,particularly rainwater or other precipitation, will contact the tonneaucover. To that end, the water is to be kept out of the truck bed whenthe tonneau cover is shrouding the truck bed. This makes watermanagement a consideration.

Accordingly, an aspect of this water management of the presentdisclosure is with regard to the connection between a flexible hingemember and a connecting cover section of the tonneau cover. In thiscase, the flexible hinge member connects to a cover section, andparticularly, a formed or extruded metal frame member portion of thecover section. The flexible hinge member may be made from a rubber orflexible resilient polymer material. Because of the contrast inmaterials, such as extruded aluminum and resilient polymer, a seambetween the two materials may exist that can form a gap therebetween.Such a gap can be especially prominent when the flexible hinge member isbent as adjacent cover sections are being folded. This gap may create apathway between the exterior of the tonneau cover and the interior ofthe truck bed. A pathway makes it easy for rainwater or otherprecipitation to migrate through the gap from outside to inside thetruck bed. This is the case even when the tonneau cover is not foldedbut lying flat covering the truck bed. This is because, despite theinherent memory of the resilient flexible hinge member, that memory maynot be enough to eliminate any gap or spacing between the flexible hingemember and the cover section.

An illustrative embodiment of the present disclosure provides a sealingstrip that is located at the juncture between the flexible hinge memberand the cover section. This sealing strip has a length, width, andthickness sufficient to fill in any gap formed at the seam between thecover section and the flexible hinge member. In a further illustrativeembodiment, the sealing strip contact surfaces engaging the coversection and flexible hinge member may include an adhesive to providesecurement between the sealing strip and the cover section, as well asthe sealing strip and the flexible hinge member. The adhesive serves adual role of preventing gaps between the cover section and hinge member,and assists in securing the two structures together.

A side detail view of a portion of tonneau cover 14 is shown in FIG. 22.Cover section 24 is depicted pivotally coupled to cover section 22 viaflexible hinge members 166 and 168 with narrow intermediate panel 164located therebetween. Panel 188 of cover section 24 is fitted intochannel 240 of frame member 194. Latch channel 242 is shown locatedadjacent channel 240 and configured to receive latching assembly 32(see, also, FIG. 2). Illustratively, extending from latch channel 242opposite channel 240 is arm 263 of hinge clasp channel structure 262. Agrip flange 264 extends from arm 263 and is oriented inwardly towardhinge clasp channel structure 262 such as illustratively shown. Flexiblehinge member 168 includes a corresponding wrap-around arm 266 with alikewise corresponding grip flange 268 that engages grip flange 264 ofhinge clasp channel structure 262 as illustratively shown.

An arm 270 of flexible hinge member 168 includes a longitudinallyextending seal channel 272 that faces arm 263 bounding hinge claspchannel structure 262. Sealing strip 274 fits into seal channel 272between arm 270 of flexible hinge member 168 and arm 263 of hinge claspchannel structure 262. Sealing strip 274 may be made from foam, rubber,acrylic adhesive, urethane adhesive, epoxy adhesive, pressure sensitivetapes and the like, that creates a barrier by filling the space betweenarms 263 and 270. In this way, water that may be present at the exteriorof tonneau cover 14 cannot pass through same at seam 276. Sealing strip274 serves as a barrier to prevent any such migration. Additionally,sealing strip 274 may include an adhesive the abutment between itselfand arm 263 and at arm 270. This provides a secure attachment betweenflexible hinge member 168 and frame member 194 (and, thus, cover section24).

Extending in an opposite direction, flexible hinge member 168 includesanother arm 278 with a seal channel 280 that faces arm 282, of a hingeclasp channel structure 284 on narrow intermediate panel 164. On theside of flexible hinge member 168, another sealing strip 286 is locatedin seal channel 280 abutting both arms 278 and 282 to create a barrierat seam 288 in similar form to that identified with respect to sealingstrip 274. Additionally, flexible hinge member 168 includes wraparoundarm 290 extending therefrom and a grip flange 292 which engages gripflange 294 that extends from arm 282. Also similar to sealing strip 274,sealing strip 286 may include adhesive at the abutment between itselfand arm 278 and at arm 282. This creates a securement between flexiblehinge member 168 and narrow intermediate panel 164. And again, thisprevents water that may be exterior to tonneau cover 14 from migratingthrough same at seam 288 in order to get to interior 16 of truck bed 4.Accordingly, despite cover section 24 being pivotable with respect tonarrow intermediate panel 164, water is prevented from entering theinterior 16 of truck bed 4 at this juncture.

These same structures may exist for flexible hinge member 166. An arm270 includes a longitudinally extending seal channel 272 that faces arm263 bounding hinge clasp channel structure 262. Sealing strip 274 fitsinto seal channel 272 between arm 270 of flexible hinge member 166 andarm 263 of hinge clasp channel structure 262. Sealing strip 274 servesas a barrier to prevent any such migration. Sealing strip 274 may alsoinclude an adhesive at the abutment between itself and arm 263 and atarm 270 to provide a secure attachment between flexible hinge member 168and frame member 194.

Extending in the opposite direction, flexible hinge member 166, likeflexible hinge member 168, includes another arm 278. Seal channel 280 ofarm 278 faces arm 282 of a hinge clasp channel structure 284 on narrowintermediate panel 164. On the side of flexible hinge member 166,another sealing strip 286 is located in seal channel 280, abutting botharms 278 and 282, to create a barrier at seam 288. Additionally,flexible hinge member 166 includes wraparound arm 290 extendingtherefrom and including grip flange 292 which engages grip flange 294that extends from arm 282. Sealing strip 286 may include adhesive at theabutment between itself and arm 278 and at arm 282. This creates asecurement between flexible hinge member 166 and frame member 196 ofcover section 22. And again, this prevents water that may be on exteriortonneau cover 14 from migrating through same at seam 288 in order to getto the interior of truck bed 4. Thus, water is prevented from enteringthe interior 16 of truck bed 4 at cover section 22.

A perspective isolated detail exploded view of a portion of tonneaucover 14 (similar to FIG. 13) is shown in FIG. 23. This portion oftonneau cover 14 includes cover sections 22 and 24. As shown, panel 188fits into channel 240 of frame member 194. It is appreciated that theother frame members that bound cover sections 18, 20, and 22 employsimilar channel configurations to fit their panels in respective framemembers. Frame member 194 also includes a latch channel 242 configuredin size to receive latching assembly 32. Also shown is prop rods mounts232 and 234. Fillers 244 and 248 fill any voids adjacent the peripheryof the cover, between end caps such as end caps 222 and 224, or at hingeareas, adjacent perimeter seals such as perimeter seal 132. Flexiblehinge member 168 is shown located between frame member 194 and narrowintermediate panel 164.

Located on the longitudinal extent of arm 263 of hinge clasp channelstructure 262 is sealing strip 274. Sealing strip 274 extends along anywidth of tonneau cover 14 to seal seam 276 (see FIG. 22) between framemember 194 and flexible hinge member 168. Because arm 270 of flexiblehinge member 168 extends and is fitted over sealing strip 274, whichitself is shown attached to arm 263 of hinge clasp channel structure262, a seal is created between frame member 194, and flexible hingemember 168. Opposite frame member 194 is narrow intermediate panel 164with sealing strip 286 located on arm 282. As on frame member 194,sealing strip 286 may extend the longitudinal length of arm 282 in orderto provide a barrier between arm 278 of flexible hinge member 168 andnarrow intermediate panel 164.

This view also depicts the longitudinally-extending character ofcomponents of cover section 22. Particularly, shown herein are portionsof the longitudinally extent of panel 198, and frame member 196.Flexible hinge member 166 flexibly connects narrow intermediate panel164 to frame member 196. Further shown is the longitudinal extent of arm263 on narrow intermediate panel 164 along with hinge clasp channelstructure 262 and sealing strip 274. Arm 270 of flexible hinge member166 extends and is to be fitted over sealing strip 274. A seal iscreated between narrow intermediate panel 164 and flexible hinge member166. Opposite narrow intermediate panel 164 is narrow frame member 196with sealing strip 286 located on arm 282.

A side detail view of portions of tonneau cover 14 (similar to FIG. 14)are shown in FIG. 24. This view depicts portions of cover sections 20,22, and 24. Cover sections 20 and 22 are attached to base intermediatepanel 158 via flexible hinge members 160 and 162. Similarly, narrowintermediate panel 164 is pivotally coupled to cover sections 22 and 24via flexible hinge members 166 and 168. It is further notable from thisview that the wider width of base intermediate panel 158 joins coversections 20 and 22 located toward tailgate 10 of truck 2. In contrast,the narrower width of narrow intermediate panel 164, between coversections 22 and 24, is located towards the cab section 12 of truck 2when tonneau cover 14 is unfolded and laid flat on truck bed 4.

This view further depicts how the sealing strips fit at all of thejunctures between the panels and hinges. For example, sealing strips286, and 274 are located on flexible hinge member 172 located betweencover sections 18 and 20. Sealing strips 286 and 274 are located onflexible hinge member 162 and between cover section 20 and baseintermediate panel 158. Sealing strips 286 and 274 are located onflexible hinge member 160 located between base intermediate panel 158and cover section 22. Sealing strips 286 and 274 are located on flexiblehinge member 166 located between cover section 22 and narrowintermediate panel 164 (see, also, FIG. 23). Sealing strips 286 and 274are, lastly, located on flexible hinge member 168 located between narrowintermediate panel 164 and cover section 24 (see, also, FIGS. 22 and23).

Cover Panel Section Handle

Folding the cover sections to their stacked stored position is generallynot a difficult task. Each cover section, starting at the tailgate end,is simply lifted and folded onto the next adjacent panel until they areall folded up near the cab section of the pickup truck. Conversely,unfolding most of the cover sections back to the tonneau cover's laidflat position shrouding the truck bed is largely conventional as well.The cover sections are simply unfolded in an opposite direction of howthey were originally folded.

Illustratively, with the type of cover disclosed herein, space existsbetween at least some of the sections when folded. Being able to grabthe cover sections to unfold same is, therefore, not a particularlychallenging task—except for one of the cover sections. The last coversection of the tonneau cover that shrouds the bed section, adjacent thetailgate end, is folded flat up against the top surface of the adjacentcover section. There is no appreciable space between the cover sections.In addition, there are no features that one could grasp to unfold thelast cover section over the truck bed, thus, posing a challengeunfolding this last cover section.

According to the illustrative embodiment, a cover section handle may beaffixed to the underside of the cover section to provide a graspingstructure for an operator to grip and move the cover to its unfoldedshrouding position over the truck bed. In an embodiment, the coversection handle may be located on the underside of the cover sectiondistal from the cover section's hinge. This allows the operator tocreate a moment of force on the hinge by lifting on the cover sectionhandle to pivot the cover section over.

In addition, the cover section handle being located on the underside ofthe cover section means that it will be positioned extending upwardswhen the last cover section is folded over onto the adjacent coversection, but will be concealed in the interior of the truck bed when thecover section is unfolded over and located adjacent the tailgate (whenthe tailgate is positioned upward and latched). It is appreciated thatthe cover section handle in some embodiments may be located anywhere onthe cover section that makes it easier for the operator to move thatcover section to another position.

Another perspective view of tonneau cover 14 shrouding the portion ofinterior 16 of bed section 4 is shown in FIG. 25. This view is similarto that shown in the prior figures except that (1) cover section 18 isonly partially folded over cover section 20; and (2) cover section 18 isshown in a partially exploded view. With regard to the latter, coversection 18 is composed of panel 218 bounded by frame member 216, endframe panel 220, and endcaps 222 and 224. A tailgate seal 184 is affixedto end frame panel 220 and configured to seal between tonneau cover 14and tailgate 10 when tonneau cover 14 is in its closed shrouded position(see, FIG. 1).

Also located on end frame panel 220 are endcaps 226 and 228 to be fittedon the ends thereof. A latching assembly can also be fitted within achannel in end frame panel 220. Further included are cover sectionhandles 300 and 302 attachable to opposing sides of end frame panel 220.It is appreciated that cover section handle 300 may be located on oneside of cover section 18, adjacent the longitudinally extending latchingassembly 32, while cover section handle 302 may be located on theopposite side of cover section 18, distal from cover section handle 300.Opposite end frame panel 220 is flexible hinge member 172 that pivotallycouples cover section 18 to cover section 20.

Another perspective view of pickup truck 2, with tonneau cover 14 in apartially covered condition similar to that shown in FIG. 25, is shownin FIG. 26. This view differs from FIG. 25 in that cover section 18 isassembled and shows hand 304 of an operator engaging cover sectionhandle 300 to pivot cover section 18 in direction 35 to fully coverinterior 16 of truck bed 4.

As can be appreciated from FIG. 2, when cover section 18 is folded overonto cover section 20, there is no appreciable space between the twocover sections. As such, it is more difficult to lift and move coversection 18 in direction 35 as compared to the other cover sections 20,22, and 24. This is because a space exists between cover sections 20,22, and 24 when folded. Accordingly, to assist unfolding cover section18 in direction 35, for example, hand 304 of the operator lifts at coversection handle 300 (or by lifting cover section handle 302 as well, orin the alternative) to facilitate that easier lifting.

A perspective detail view of the underside of cover section 18 is shownin FIG. 27. This view depicts panel 218, end frame panel 220, latchingassembly 32, and tailgate seal 184. Additionally, cover section handle302 is attached to cover section 18 by handle bracket portion 306, whichincludes a fastener 308 to, illustratively, attach cover section handle302 to end frame panel 220. In an illustrative embodiment, end framemember 220 may include an extending channel 310 that abuts handlebracket portion 306 and receives fastener 308 to secure cover sectionhandle 302 onto end frame panel 220. It is appreciated that coversection handle 300 may be attached in the same manner. It will befurther appreciated by the skilled artisan upon reading this disclosurethat, in addition to the embodiments shown, the cover section handle maybe integrally formed on end frame panel 220, be attached to any partthereof, or attached to any other portion of cover section 18. Infurther embodiments, the handle may be extruded along the width of panel218, combined in frame panel 220, formed into tailgate seal 184, orcombined with end caps 220 or 224. The point is that the cover sectionhandle be a grippable structure extending in some manner from coversection 18, allowing hand 304 to grasp the cover section handle in orderto move the cover section. In alternate embodiments, a secure coversection handle may attach to any of cover sections 20, 22, and 24, asdesired.

Tonneau Cover Wall Rail and Clamp

Another illustrative embodiment of the present disclosure dispenses withthe need for any gutter or other draining mechanisms for rainwater andother like precipitation that might pass through the interface betweenthe tonneau cover and the truck bed sidewall. This disclosure includes anew water mitigation system at the interface between the side of thetonneau cover of the truck bed sidewall that illustratively includes aperimeter seal that extends from the side of the tonneau cover and/or arail that both couples to the tonneau cover at the sidewall. The railincludes a portion that sets on the top of the truck bed sidewall. In anillustrative embodiment, the tonneau cover sets on the rail such that atleast a portion of the tonneau cover is set above the sidewall. A flangemay extend from the rail over the top surface of the truck bed sidewallat its top inner periphery. As such, the rail becomes essentially thetop inner corner of the truck bed sidewall. The perimeter seal extendingfrom the side of the tonneau cover is sized to shroud the flange portionof the rail that extends over the top of the truck bed sidewall. Withthis combination, the effective top inner periphery of the truck bedsidewall is covered, thereby preventing water, such as rainwater, snow,or other exterior precipitation, from entering into the interior of thetruck bed between the sidewall and the cover. It is appreciated thatthroughout this disclosure one sidewall may be discussed. It isunderstood, however, that such disclosures herein apply to bothsidewalls, and even other walls as well, if applicable.

An end cross-sectional view of sidewall 8 of truck bed 4 is shown inFIG. 28. An illustrative version of sidewall 8 includes a top sidewallcap 318 illustratively attached to sidewall 8 via retaining clips 320.It is appreciated, however, that such sidewalls and top surfaces of samemay be configured in a variety of different manners. Some sidewalls mayinclude a top cap such as top sidewall cap 318. Other sidewalls mayinclude a bent-metal formed top panel that is part of the formedsidewall. It is further contemplated that the disclosures herein are notdependent on the precise character of the top panel on the sidewall.Additionally, with respect to the disclosures herein, despite beingdiscussed with reference to top sidewall cap 318, the disclosure isbelieved to be employed equally as well on any type of sidewall toppanel. For this illustrative sidewall 8, a down-turned flange 322 islocated at the inner periphery of truck bed 4. As illustratively shownherein, a portion of top sidewall cap 318 extends downward adjacentdown-turned flange 322. It is appreciated, however, that in other truckdesigns, the top bed wall cap may not include an extending down-turnedflange like extending down-turned flange 322. Either configuration issuitable for this disclosure. Furthermore, the shown down-turned flange322, as part of sidewall 8 (as well as the down-turned flange forsidewall 6), is illustrative only. The embodiments in this disclosureare contemplated to be used on any variety of truck bed sidewalls.

In an illustrative embodiment, clamp assembly 156 is shown coupled torail 30 and positioned to clamp onto down-turned flange 322 of sidewall8. Clamp assembly 156 includes a clamp mount 324 that includes anupward-extending flange 326 that fits into slot 328 of rail 30. Clampmount 324 also includes a planar surface 330 that rests on support 332of rail 30. Upward-extending flange 326, in combination with planarsurface 330 supported in slot 328 and support 332, will assist inkeeping clamp assembly 156 seated on rail 30, even when clamp assembly156 is not tightly clamped onto down-turned flange 322, as shown herein.To that end, opposite clamp mount 324 is clamp back 334 coupled togethervia clamping fastener 336, which extends therebetween. An illustrativeserrated-type gripping surface 338, on clamp back 334, will abutdown-turned flange 322 when clamping fastener 336 is rotated. Thisconfiguration will draw clamp mount 324 and clamp back 334 toward eachother in directions 340 and 342, respectively. An adjustment screw 348is disposed through clamp base 350 and engages clamp back base 352 toallow clamp back 334 to be moved vertically in either directions 344 or346. This allows the clamp assembly 156 to accommodate down-turnedflanges of different character on different types of truck bedsidewalls. It is appreciated that clamping fastener 336 may be disposedthrough a slot (not shown) disposed through clamp mount 324 so clampback 334 can be moved both vertically in directions 344 and 346, as wellas horizontally or in a clamping position in direction 342.

Also shown in FIG. 28 is rail 30. A portion of rail 30 (as well as rail28 on sidewall 6) is located above the top plane or surface 354 of topsidewall cap 318, as well as the interior periphery of truck bed 4 atdown-turned flange 322.

Another end cross-sectional view of a portion of sidewall 8 of truck 2,similar to the view shown in FIG. 28, is shown and FIG. 29. Adistinction in this view from that shown in FIG. 28 is that coversection 18 is shown lowered onto rail 30 and latched thereto. Latch 374,of latching assembly 32, is disposed in slot 328 of rail 30, partiallydefined by knuckle 364 and member 370 forming latch receiving channel366. Knuckle 364, in conjunction with extension 362, creates an abutmentbetween latch 374 and flange 376 of endcap 222 to sandwich rail 30therebetween. This secures cover section 18 onto rail 30. Further shownin this view is panel 218 fitting into endcap 222. Perimeter seal 132includes tabs 378 fitted in channel 380 formed in endcap 222. Thisassists securing perimeter seal 132 to cover 14.

In addition, perimeter seal 132 includes a flap 382 extending from coversection 18 over top sidewall cap 318 on top of sidewall 8. As furthershown in this view, flap 382 also extends over panel portion 358, andtab end 360 of rail 30 illustratively contacting the top of top sidewallcap 318 shrouding this portion of rail 30. An illustrative down-turnedtab 384 extends over tab end 360 to provide additional sealingcapabilities to keep rain or other precipitation from entering interior16 of truck bed 4. Accordingly, as shown in this view, dual barriersexist between tab end 360 of panel portion 358 and flap 382 to providethe sealing function. It is appreciated that, although this sealingfunctionality is described with respect to perimeter seal 132 of coversection 18, the same structures apply on all of the additional coversections 20, 22, and 24. These descriptions also apply to the oppositeside of cover section 18, adjacent sidewall 6, along with the oppositesides of the other cover sections 20, 22, and 24. By creating this dualseal, essentially along both sides of tonneau cover 14, rainwater andother precipitation cannot get through this interface.

Also shown in FIG. 29 is clamp assembly 156 clamped onto down-turnedflange 322 and illustratively a portion of top sidewall cap 318 onsidewall 8. This secures rail 30 to sidewall 8. It is appreciated thatmultiple clamp assemblies 156 may be placed along rail 30 to clamp sameto sidewall 8 as shown herein. In addition, a plurality of clampassemblies 156 may attach rail 28 to sidewall 6 in the same mannerdescribed herein. With respect to rail 30 and sidewall 8, as shown inthis view, clamping fastener 336 draws clamp mount 324 and clamp back334 together to sandwich down-turned flange 322 and leg member 368 ofrail 30, as well as an illustrative down-turned tab 386 of top sidewallcap 318 to secure rail 30 to sidewall 8. Adjustment screw 348 may bemoved as necessary to move clamp back 334 as needed. This assistsclamping rail 30 to sidewall 8. It is appreciated that a plurality ofsuch clamp assemblies 156 may be positioned along rail 30 and beadjusted in the aforedescribed manner to ensure rail 30 is secured tosidewall 8. Similarly, an additional plurality of clamp assemblies 156may also be used in in the same manner described, but attaching rail 28to sidewall 6 opposite rail 30.

An end cross-sectional exploded view of sidewall 8, with clamp assembly156 and cover section 18, is shown in FIG. 30. This view further showsthe illustrative attachment of top sidewall cap 318 attached to the topof sidewall 8, along with down-turned tab 386. The exploded view ofcover section 18 includes perimeter seal 132 with its tabs 378 that arereceived in channel 380 of endcap 222. Also shown with respect toperimeter seal 132 is flap 382 with down-turned tab 384 sized to engagethe top of top sidewall cap 318 to provide a barrier seal for interior16 of truck bed 4. It is appreciated that perimeter seal 132 (and 133)may be made from a rubber, rubber-like material, or resilient polymer.

Endcap 222 includes flange 376 sized and configured to extend oversidewall 8. Channel 380 is sized to receive tabs 378 of perimeter seal132 (see, also, FIG. 29). An illustrative channel in endcap 222 receivesa portion of panel 218. Latching assembly 32, with latch 374 extendingtherefrom, is coupled to cover section 18. It is appreciated that thesesame structures described herein with respect to this end of coversection 18 may be employed on the opposed end of cover section 18 aswell. Furthermore, the structures may also be included on both sides ofthe other cover sections 20, 22, and 24. It is still further appreciatedthat illustrative latch assemblies and other structures related to thecover sections may engage rails 28 and 30 as well.

A seal member 388 may illustratively be positioned between leg member368 and down-turned tab 384 to provide a sealing function between rail30 and top sidewall cap 318. Lastly, clamp assembly 156 is shownincluding clamp mount 324, clamp back 334, clamping fastener 336, andadjustment screw 348.

End sectional and underside views of tonneau cover 14 is shown in FIGS.31, 32, 33, and 34. These views depict how clamp assembly 156 is coupledto the rail 30. As shown in FIG. 31, for example, upward-extendingflange 326 of clamp mount 324 of clamp assembly 156 is placed in slot328 of rail 30. Clamp assembly 156 is then pivoted in direction 333, asshown in FIG. 32. Planar surface 330 is, thus, supported by support 332of rail 30 to support clamp assembly 156. Prior to clamping rail 30 ontodown-turned flange 322 of sidewall 8 of the truck bed this view showsclamp back 334 not yet engaged with down-turned flange 322. Support ofplanar surface 330 on support 332 and upward-extending flange 326 fittedin slot 328 helps keep clamp assembly 156 hung onto rail 30 while in theprocess of installing same onto sidewall 8 without clamp assembly 156falling off or needing some other support prior to clamping, as shown inFIGS. 33 and 34.

Tonneau Cover Multi-Piece Rail

Another illustrative embodiment of the present disclosure also providesa pickup truck that includes a tonneau cover having rails that areattached to the truck bed sidewalls. These rails support the tonneaucover and help keep water and other elements from migrating between theinterface of the tonneau cover and truck bed side walls. In addition,the rails are composed of multi-piece rail sections that combine to formthe full-length rails.

An advantage of multi-piece rails is for shipping the tonneau cover.Overall carton size must be increased when shipping a tonneau cover withfull length 6 foot long rails. A 6 foot long carton may be unwieldy forcommon carriers such as the post office, FedEx and UPS, for example.With multi-piece rails, the carton size may be reduced, which is betterfor sellers, shippers, and, ultimately, customers.

In an embodiment of the present disclosure, rail assemblies may includea plurality of rail sections that can be combined together to form arail that extends the length of the sidewall of the pickup truck's truckbed. A block, bracket, or other like structure may be attachable to bothrail sections to attach them together. This connection can apply to railsections that form the rails on both sidewalls of the truck bed.Accordingly, when shipping the tonneau cover, the rails are broken downinto rail sections of lesser length than the rails as a whole andpackaged in a carton that is of lesser size than the carton wouldotherwise be with rails that extend the full length of the truck bedsidewalls. This results in shipping cartons for the tonneau cover thatare overall shorter than the carton otherwise would be. This results inbetter shipping options for the tonneau cover, particularly with respectto residential delivery.

Another perspective view of truck 2, with tonneau cover 14 attached ontosidewalls 6 and 8 of truck bed 4, and in folded condition similar toFIG. 5, is shown and FIG. 35. Here, cover sections 18, 20, 22, and 24are folded over and stacked vertically onto bulkhead panel assembly 26.Prop rods 150 and 152 are each both coupled to cover section 24 and ontorails 28 and 30, respectively. A distinction between the views of FIG. 5and FIG. 35 is that mechanical catch assembly 33, as shown in FIG. 5,has been removed for illustration purposes to show rail coupling block390 illustratively located underneath. In this illustrative embodiment,rail 30 is not a single longitudinally extending rail. Instead, rail 30is composed of multiple rail sections that are connected together toform the full rail that extends along sidewall 8 as shown herein.

Rails, such as rails 28 and 30, as shown in their installed form, tendto be the longest structures of tonneau cover 14. This can become anissue for shipping purposes. For example, a tonneau cover, such astonneau cover 14 shown in its folded condition in FIGS. 5 and 35, mayhave a compact dimension of about 5.5 feet wide by about 1.3 feet highby about 0.5 feet thick. When disassembled, the cover portion alone onlyoccupies a space of about 5.5 feet by about 1.8 feet by about 0.3 feet.These dimensions are acceptable for shipping through a common carriersuch as UPS, FedEx, etc. But when including the rails, which may be aslong as 6 to 8 feet, the shipping carton for the cover and rails needsto be that same length as well. This makes it potentially difficult forresidential delivery.

Accordingly, the present disclosure includes rails, such as rails 28 and30 that are composed of rail sections. These rail sections each have anoverall length that is less than the total length of the rails (e.g.,less than 6 feet). This makes the overall packaging for tonneau cover 14much reduced, which translates into better shipping options forresidential and commercial shipping.

As further shown in FIG. 35, rails 28 and 30 extend the length ofsidewalls 6 and 8, respectively, just as full length rails. The additionof rail coupling block 390 connects rail sections 392 and 394 to formrail 30. The same is the case (although not shown in this view) withrail 28 having its own rail sections similar to rail sections 392 and394 to form the full length rail 28.

A perspective detail view of rail 30 is shown in FIG. 36. Rail 30 isshown composed of rail sections 392 and 394, which are joined togetherand attached via rail coupling block 390. Clamp assemblies 156 may becoupled to each of rail sections 392 and 394 at slot 328. It isappreciated that multiple clamps 156 may be coupled to each of railsections 392 and 394. Additionally, although only rail 30 is shown inthis view, the embodiments and disclosures herein apply to rail 28 aswell.

With regard to rail coupling block 390, it illustratively may include across-sectional profile that complements the cross-sectional profile ofboth rail sections 392 and 394, so as to fit thereon as illustrativelyshown. Rail coupling block 390 may expand across both rail sections 392and 394, and use fasteners or other like structures to secure railsections 392 and 394 to rail coupling block 390.

An exploded perspective detail view of rail 30 is shown in FIG. 37.Clamp assemblies 156 is shown in exploded view, including clamp mount324, clamp back 334, clamping fastener 336, and adjustment screw 348.Shown in clamp mount 334 is slot 325 sized to receive clamping fastener336 allowing same to move within slot 325 to adjust clamp back 334 withrespect to the other components of clamp assembly 156 (or the othercomponents with respect to clamp mount 324). Each clamp assembly 156shown in this view is configured to fit into slot 328 formed in each ofrail sections 392 and 394, respectively. Each slot 328 includes anextending member 370 and support 332 which contribute to defining thecross-sectional profile of each of slots 328. An extension 362 dependingfrom panel portion 358, along with finger 364, forms a latch receivingchannel 366. Rail coupling block 390 engages both rail sections 392 and394 by including features that complement the cross-sectional profile ofrail sections 392 and 394. For example, a groove 398 and slot 400longitudinally disposed along the back side of rail coupling block 390complement the cross-sectional profile of rail sections 392 and 394,particularly, slot 328, with support 332 and member 370, as shown.Similarly, a corresponding latch slot 402 with flange 404, all of whichare longitudinally extending, as shown, fit into latch receiving channel366 having the profile formed by panel portion 358, extension 362, andfinger 364. It will be appreciated by the skilled artisan upon readingthis disclosure that the complementary cross-sectional profile formed inrail coupling block 390 is longitudinally extending on the block so thatit may fit into both rail sections 392 and 394 (see, also, FIG. 36).

A plurality of fasteners 406 illustratively extend through bores 407. Inan illustrative embodiment, bores 407 may include threads which receivefasteners 406. Because the shape of groove 398 and slot 400 arecomplementary to the shape formed by slot 328 with support 332 andmember 370, this illustrative embodiment of rail coupling block 390 onlycouples to rail sections 392 and 394 by sliding in at theircross-sectional ends 408 and 409. Once rail coupling block 390 is fittedinto both rail sections 392 and 394, rail coupling block 390 cannot beremoved by pulling it outward in a direction transverse to thelongitudinal extent of rail 30. The fasteners 406 extend through bores407 to essentially wedge rail coupling block 390 in slots 328 byfasteners 406 pushing against rail sections 392 and 394 at slot 328.This secures rail coupling block 390 against rail sections 392 and 394.

It will be appreciated by the skilled artisan upon reading thisdisclosure that other coupling structures may be employed such aspredrilled openings in the coupling block aligning with predrilledopenings in the rail sections and attached together by fasteners;clamping structures not unlike clamp assembly 156 that clamps onto bothpanel sections. In addition, in other embodiments, rail 30 (as well asrail 28) may be split into three or more sections as opposed to just twosections. Multiple coupling blocks or other structures may be employedto couple the three or more rail sections together. Furthermore, acoupling seal 410 may be positioned between rail sections 392 and 394.Rail coupling block 390 may include a slot 411 configured to receive atleast a portion of coupling seal 410. It is appreciated that couplingseal 410 has a shape that complements the cross-sectional shape of atleast a portion of ends 408 and 409 of rail sections 392 and 394. Thisprevents moisture, such as precipitation, from seeping at the seamformed between connecting rail sections 392 and 394.

A plurality of perspective detail progression views showing the assemblyof rail sections 392 and 394 are shown in FIGS. 38A, 38B, and 38C. Withrespect to FIG. 38A, it shows clamp assembly 156, rail coupling block390, and coupling seal 410. From this view, rail coupling block 390 isinserted into rail section 394 at end 409 as shown. Rail coupling block190 is also shown in this first view partially extending out from end409 so as to fit into end 408 of rail section 392. This view furthershows the longitudinal extent of slot 400 and how it is configured toreceive member 370 when fitted into slot 328 in rail section 392.

The view in FIG. 38B is similar to that of FIG. 38A except that the nextstep in assembling rail 30 is to place coupling seal 410 onto railcoupling block 390 illustratively adjacent rail section 394. It isappreciated from this view how coupling seal 410 mimics thecross-sectional profile of rail section 394 (as well as rail section392). This creates a mating seal between rail sections 392 and 394. Atthis point, rail section 392 may be movable in direction 412 to slideonto rail coupling block 390. To that end, as shown in FIG. 38C, railsection 392 has been moved fully in direction 412 onto rail couplingblock 390 and abutting coupling seal 410. Using fasteners 406 (as shownin FIG. 37), rail sections 392 and 394 are coupled together withcoupling seal 410 sandwiched in between. This forms the full rail 30 (orrail 28) that extends the length of truck bed sidewall 8 (or sidewall 6)upon which tonneau cover 14 sets on as shown in the previous drawings.

The utility of the multi-piece rail design of the present disclosureenables the shipping carton to be a reduced size. Because of theincreased popularity of common carriers employed to ship product,particularly to residential addresses, carton size for many products hasreceived a new level of scrutiny. Where once it may have been anon-issue to ship tonneau covers with 6 foot long rails, it has nowbecome an issue.

A perspective view of a folded prior art tonneau cover 413, with priorart single component rails 414 and 415 packaged in prior art carton 416,is shown in PRIOR ART FIG. 39. It is appreciated from this view how thelength of folded tonneau cover 413 is much shorter than the length ofsingle component prior art rails 414 and 415. This makes the length,identified by L′, about the length of single component prior art rails414 and 415 which are longer than tonneau cover 413. This creates deadspace 417 between the end of tonneau cover 413 and prior art carton 416as shown.

A perspective view of folded tonneau cover 14 of the present disclosure,along with rail sections 392 and 394, is shown in FIG. 40. It isappreciated from this view how the length of rail sections 392 and 394are not long enough that they extend beyond the length of folded tonneaucover 14 shown therein. Indeed, their individual lengths are quite less.This means that the overall length, identified by L of carton 418, issubstantially less than the overall length L′ of prior art carton 416.This means the carton will have illustrative dimensions of about 5.6feet long by about 2.3 feet wide by about 0.5 feet high, thereby makingit sufficient to be delivered by common carriers such as UPS and FedEx.

Another perspective view of carton 418, from FIG. 11, is shown in FIG.41. This view helps appreciate the difference in size between prior artshipping carton and the current shipping carton. As shown herein, theoriginal prior art carton 416, as shown in FIG. 39, has a length asrepresented of L′. In contrast, carton 418 has a length L. Asrepresented in dashed lines, the shipping volume saved 419 has a lengthL″. In other words, the shipping volume saved 419 from prior art carton416 results in a smaller carton 418 having a length L that is moreaccommodating for common carriers.

A perspective exploded view of carton 418 that includes tonneau cover 14and rail sections 392 and 394 is shown in FIG. 42. This viewdemonstrates how tonneau cover 14 may be packed with packing material420 and 421 and placed in lower carton tray portion 422. Rail sections392 and 394 may also be fitted in slots or other holding structures ofpacking material 421. Prop rods 150 and 152 may be fitted in packingmaterial 421 as well. An additional box 424 may be used for parts andaccessories. A top carton lid 426 may be placed over top to form carton418. Again, this can only be accomplished in appropriate dimensions whenrails 28 and 30 are split into at least two rail sections 392 and 394each.

Mechanical Catch Assembly

Because of the expansive length of the truck bed, and hence its cover,it can be useful to have securement points along the length of the coverand the sidewalls. Typically, tonneau covers include a first latchassembly directed towards the inside of the truck bed to keep at least aportion of the cover secured to the rail or sidewalls of the truck bed.This first latching assembly is typically located towards the end of thecover by the tailgate so an operator may activate the latches to unlatchthem from the sidewall or rail. Additional manually activated latchingassemblies may be placed periodically along the length of the coveradjacent the sidewalls. Hence, a series of manually operated latches areregularly positioned along the length of the cover to keep same securedalong the rail or sidewall.

An illustrative embodiment of the present disclosure provides analternative to these additional manually actuated latches used to securethe length of the tonneau cover to the sidewalls. Although a manuallyoperated latch can still be placed at the tailgate end of the cover toselectively initiate releasing the cover from the rail or sidewalls, oneor more catch assemblies may be employed that do not require manualunlatching of the cover to fold or roll it up to its stored position foruncovering the truck bed. The catch assembly still secures the cover tothe bed sidewalls (or rail) when the cover is unrolled flat over thetruck bed, but during the act of unrolling or unfolding the cover, thecatch assembly releases the cover without further effort by theoperator.

A further illustrative embodiment of the present disclosure includes amechanical catch assembly that is activated by the movement of the coverwith respect to the mechanical catch assembly. This causes themechanical catch assembly to either grab the cover when being unrolledor unfolded flat, or release from the cover when being rolled or foldedfor stowage.

An embodiment of the mechanical catch assembly may include a catch basethat is secured to a rail which itself is secured to a sidewall of thepickup truck bed. A pivoting lever arm or other like structure may bespring-loaded or otherwise biased keeping it and a movable flange orplunger in a non-latched condition. This allows the cover to be foldedor rolled without being impeded or necessitating any further action onthe part of the operator to unsecure the cover from the rail orsidewall. Conversely, when the cover is being unfolded flat to shroudthe truck bed, the cover can engage the lever arm which then moves theplunger. The plunger may serve as a catch that, upon movement, engagesthe cover to secure same to the rail.

These mechanical catch assemblies may be periodically spaced along thesides of the rail or sidewall to latch to the cover at multiplepositions, to prevent anyone from separating the cover from the rail togain unauthorized access to the truck bed underneath.

Illustratively, the mechanical catch assembly may include a movable armattached to the rail that is engageable by a foot member that isattached to the underside of the cover. This engagement moves the leverarm, which extends the movable plunger or catch, that itself isengageable with a panel catch also extending from the underside of thecover, so as the cover unfolds and the foot engages the lever arm, thecatch extends and engages the panel catch, thereby securing the catchassembly (attached to the rail) to the cover. When folding or rollingthe cover, the foot releases from the lever arm causing the plunger orlatch to release from the panel catch, thereby unlatching the cover fromthe rail and allowing the cover to be further folded or rolled forproviding access to the truck bed underneath. This is all done withoutthe operator having to perform any unlatching steps.

As shown in FIG. 3 mechanical catch assembly 33 is attached to rail 30.It is appreciated that a plurality of such mechanical catch assemblies33 may be placed on both rail 30, as well as rail 28. Each of theplurality of mechanical catch assemblies 33 may be positioned adjacentto one of the cover panels so as to secure the cover panel to the railwhen the cover panel is laid flat on same. Conversely, mechanical catchassembly 33 may release from its corresponding cover panel when thecover panel is being folded to uncover truck bed 4.

A utility of mechanical catch assembly 33, as further identified herein,is to provide a securement for the cover panels of tonneau cover 14 ortypes of covers such as flexible, folding, rolling, etc., when laid flaton rails 28 and 30 (and/or sidewalls 6 and 8). By having this securementwhen tonneau cover 14 is covering truck bed 4, thereby shroudinginterior 16, a level of security is created. Despite latching assembly32 on cover sections 18 securing same to rails 28 and 30, it might bepossible to pry an opening between any of the other cover panels 20, 22,or 24 from rails 28 and 30 (or sidewalls 6 and 8) to provideunauthorized access into interior 16 of truck bed 4. Accordingly, havinga catch that secures each of the cover panels (or the cover itself whenused with other embodiments of the cover) prevents that potential forseparation between tonneau cover 14 and truck bed 4.

A distinction, however, between mechanical catch assembly 33 andlatching assembly 32 is that latching assembly 32 requires the operatorto actively engage latches on latching assembly 32 in order to unlatchcover panel 18 from rails 28 and 30. In contrast, mechanical catchassembly 33 does not require direct engagement by the operator to eithersecure to or release the cover sections. The mechanical catch assembliesmay be spaced apart in any desired manner and number to create asecurement between the cover and the rail as desired. To that end,mechanical catch assembly 33 is configured to engage its correspondingcover panel when its cover panel is moved to its shrouding coveredposition such as in direction 35, and then disengage from itscorresponding cover when same is being moved to its uncovered position,illustratively, in direction 37. This means the operator does not haveto independently actuate any latch assemblies each time tonneau cover 14is being folded up to access truck bed 4 underneath. At the same time,when cover sections 18 through 24 are being unfolded to shroud interior16 of truck bed 4, mechanical catch assemblies 34 will automaticallyengage and latch to those cover sections, thereby securing tonneau cover14 to truck bed 4. This makes folding and unfolding tonneau cover 14 aneasier process.

The perspective view of truck 2 shown in FIG. 4 differs from FIGS. 2 and3 in that cover panels 18 and 20 are folded completely over onto coversection 22. Illustratively, cover sections 18 and 20 have been pivotedin direction 37 as shown herein. When this happens, mechanical catchassembly 33 releases tonneau cover 14 without any further interventionby the operator other than folding the cover sections 18 and 20. It isappreciated that additional mechanical catch assemblies may bepositioned along rail 30 (as well as rail 28) to secure the other coversections onto truck bed 4.

Additionally, and as will be appreciated by the skilled artisan uponreading this disclosure, the positioning of mechanical catch assembly33, with respect to tonneau cover 14, may be at a variety of locations.For example, mechanical catch assembly 33 may be engageable with theunderside of any of cover sections 20, 22, and 24, the sides of thosecover sections, the cover sections themselves, or any panels such asintermediate panel 40 located between cover sections 20 and 22.Mechanical catch assembly 33 may conversely be located on the cover andengage the rail, sidewall, or catch located on same.

A perspective detail view of mechanical catch assembly 33,illustratively attached to rail 30, is shown in FIG. 43. It isappreciated that additional mechanical catch assemblies 33 may be placedon rail 30 at different locations, as well as on rail 28, depending onthe securement needs for the tonneau cover. For purposes of thisdisclosure, a single mechanical catch assembly 33 will be described. Theskilled artisan upon reading this disclosure, however, should notinterpret that only one mechanical catch assembly is necessarily beingused. The aforementioned plurality or multiple mechanical catchassemblies discussed are contemplated to be within the scope of thisdisclosure.

As further illustratively shown, mechanical catch assembly 33 includes abase 542 that is attachable to rail 30, illustratively, via threadedfastener 544, that when tightened, illustratively, wedges base 542against rail 30. It is appreciated, however, that any known mechanismthat can attach an assembly to a rail may be employed as a substitutefor fastener 544, and is contemplated to be within the scope of thisdisclosure. Illustratively, part of, and extending from base 542, ishousing 546 that, illustratively, contains further components ofmechanical catch assembly 33. As illustratively shown, housing 546includes an opening 548 directed towards tonneau cover 14. Because ofthe position of tonneau cover 14, with respect to mechanical catchassembly 33, a lever 550 extends outward from an opening 548 of housing546. The skilled artisan upon reading the present disclosure willappreciate that the lever shown herein is illustrative and is intendedto be a structure that encompasses various physical forms. The point isthat it is a structure being engageable by or engageable with otherstructures in order to selectively catch or release portions of tonneaucover 14. A further illustrative description of lever 550 is disclosedherein with respect to FIGS. 45 through 48.

A pin 552 is illustratively disposed through housing 546 and is thestructure about which lever 550 pivots in either directions 554 and 556.A plunger 558 is also shown selectively extending from housing 546. Asfurther described herein, plunger 558 is engageable with lever 550 andis movable by same either into or out of a panel catch 560,illustratively, located on tonneau cover 14. A bias member (see, FIGS.47 and 48) may be employed to act on plunger 558 to cause it to maintainitself in one position or another. In an illustrative embodiment, thebias member can act on plunger 558 to bias same in direction 564 so itretracts into housing 546 instead of engaging panel catch 560. Again, asfurther discussed herein, it will be when lever 550 illustratively movesin direction 556 and acts on plunger 558, applying a force greater thanthe bias force, that plunger 558 will move in direction 562 and engagepanel catch 560. This occurs when tonneau cover 14 engages lever 550moving it in direction 556. It will be appreciated that mechanical catchassembly 33 and the panel catch 560 may either be located on the coveror the rail and vice versa.

Another detail view of mechanical catch assembly 33, located on rail 30,adjacent tonneau cover 14 is shown in FIG. 44. In this view, coversection 20 is folded over cover section 22. Illustrative intermediatepanel 40 is pivotally attached therebetween. A foot pad 566 is,illustratively, coupled to intermediate panel 40 and is configured toengage lever 550 when tonneau cover 14 is unfolded and laid flat. Itwill be appreciated by the skilled artisan upon reading this disclosurethat foot pad 566 in its interaction with lever 550 does not have to beat the location of intermediate panel 40. Foot pad or other likestructure may be attached to the underside of cover section 20, forexample. Additionally, a foot pad may be integrally formed on the coveror the cover itself may be used to engage lever 550. As shown here,plunger 558 is fully retracted from panel catch 560. This means thelatching function of mechanical catch assembly 33 is presentlydisengaged.

A perspective isolated detail view of mechanical catch assembly 33coupled to rail 30 with panel catch 560 isolated from tonneau cover 14is shown in FIG. 45. This view, in contrast to the views in FIGS. 43 and44, depict mechanical catch assembly 33 in a latched condition. Asillustratively shown, lever 550 has been moved in direction 556 aboutpin 552. This movement causes lever 550 to engage plunger 558 whichmoves in direction 562 so it can engage illustrative flange 568extending from panel catch 560. Also illustrative fasteners 570 may beused to attach to the underside of tonneau cover 14.

In this illustrative embodiment, by extending plunger 558 adjacent panel560, the skilled artisan upon reading this disclosure will appreciate,the tonneau cover that panel catch 560 is attached to, will not move.Additionally, in an illustrative embodiment, panel catch 560 may have anadditional flange 572 extending away from flange 568 on the oppositeside of panel catch 560. This is so that panel catch 560 may be used onthe other side of tonneau cover 14. For ease of manufacture and cost, asingle panel catch 560 may be employed on either side of tonneau cover14.

An isolated side view of a portion of tonneau cover 14 lying flat onrail 30 and mechanical catch assembly 33, is shown in FIG. 46. This viewdepicts, like the view in FIG. 45, the positioning of mechanical catchassembly 33 when it is engaged and holding tonneau cover 14. In theillustrated embodiment, foot pad 566 is pressed down on lever 550 andattached to intermediate panel 40 hingedly attached to cover sections 20and 22 via hinges 574 and 576. It is appreciated that foot pad 566 (orother similarly functioning structure) and mechanical catch assembly 33may be located fore or aft this particular location to catch eithercover sections 20 or 22. Furthermore, additional mechanical catchassemblies may be employed on rail 30, as well as rail 28 to provideadditional selective catching functionality along the sides of tonneaucover 14. In this depiction of FIG. 46, plunger 558 is extended andengaging flange 568 of panel catch 560. Further, illustratively, plunger558 sits in cavity 578 that is formed between flange 568, the undersideof panel 22, and rail 30. This combination, illustratively, serves tomaintain a secure pocket for plunger 558 to reside in order to holdtonneau cover 14 in the closed position as shown. If someone attemptedto lift tonneau cover 14, plunger 558 prevents such movement as it isengaged to both tonneau cover 14 and mechanical catch assembly 33. Andbecause mechanical catch assembly 33 is fixedly attached to rail 30,which is fixedly attached to sidewall 8 of truck bed 4, tonneau cover 14will be unable to move.

A side elevational, sectional, and partial interior view of mechanicalcatch assembly 33 is shown in FIG. 47. Base 542 and housing 546 areshown with the latter having its facing cut away to view the structureswithin. As shown, lever 550 is pivotally coupled to pin 552 and extendsout of opening 548. An extension bar or cam 580 extends from lever 550spaced apart from pin 552 and located opposite surface 582 that engagesfoot pad 566. Cam 580 engages a flange portion 584 extending fromplunger 558. A bias member or spring 586 extends between flange portion584 and sidewall 588 of housing 546. Spring 586 is configured to bias indirections 562 and 564. With this configuration, such bias keeps plunger558 recessed in direction 564 in housing 546, as well as keeping aportion of surface 582 extended outwardly from opening 548 of housing546 making lever 550 available to be engaged by tonneau cover 14. Inother words, the positioning of plunger 558 and lever 550 shown hereinare their positioning when no other external force (i.e., the tonneaucover) acts on level 552 to move plunger 558.

Another side elevational partial cut away interior view of mechanicalcatch assembly 33 is shown in FIG. 48. This view differs from the viewshown in FIG. 47 in that now lever 550 has been moved in direction 556about pin 552. This causes cam 580 to push against flange portion 584 ofplunger 558 in direction 562 against the bias of spring 586. It iscontemplated that the weight of tonneau cover 14 will overcome the biasof spring 586 so plunger 558 will extend from opening 590 inside wall588 of housing 546. With plunger 558 extended, it engages adjacentflange 568 of the panel catch 560 as shown in FIGS. 45 and 46. Thiscreates the latching-type configuration which will prevent tonneau cover14 from being moved again after the initial cover section 18, withlatching assembly 32, is unlatched. This allows the operator to beginfolding tonneau cover 14. By doing so (as shown in FIGS. 2 through 4),the lifting movement will allow lever 550 to move in direction 554,which retracts plunger 558, releasing it from panel catch 560. Thisallows the tonneau cover 14 to be continually folded without anymanually unlatching steps to be engaged in by the operator.

In the drawings, some structural or method features may be shown inspecific arrangements and/or orderings. However, it should beappreciated that such specific arrangements and/or orderings may not berequired. Rather, in some embodiments, such features may be arranged ina different manner and/or order than shown in the illustrative figures.Additionally, the inclusion of a structural or method feature in aparticular figure is not meant to imply that such feature is required inall embodiments and, in some embodiments, may not be included or may becombined with other features. It should also be appreciated that, to theextent any subject matter disclosed in this non-provisional patentdocument conflicts with the priority application, the disclosure fromthis non-provisional patent document controls.

What is claimed:
 1. A tonneau cover for a bed of a truck, the tonneaucover comprising: first and second rails; wherein each of the first andsecond rails are configured to attach to one of two opposed truck bedsidewalls; a bulkhead panel that is secured to each of the first andsecond rails; a first cover panel section pivotably attached to thebulkhead panel; a second cover panel section; a first intermediate panelsection pivotably attached to the first cover panel section and thesecond panel section; a third cover panel section; a second intermediatepanel section pivotably attached to the second cover panel section andthe third panel section; and a fourth cover panel section pivotallyattached to the third cover panel section; wherein the first cover panelsection, the second cover panel section, the third cover panel section,and the fourth cover panel section fold to form a stack of cover panelsections; wherein the stack of cover panel sections is pivoted uprightonto the bulkhead panel which supports the stack of cover panel sectionsin an upright position; wherein the stack of cover panel sections form agenerally triangularly-shaped side profile such that a bottom portion ofthe generally triangularly-shaped side profile of the stack of coverpanel sections is wider than a top portion of the generallytriangularly-shaped side profile of the stack of cover panel sections;and wherein the second intermediate panel section sets upon the bulkheadpanel when the stack of cover panel sections is pivoted upright onto thebulkhead panel.
 2. The tonneau cover of claim 1, wherein the firstintermediate panel section has a side profile width less than a sideprofile width of the second intermediate panel section.
 3. The tonneaucover of claim 1, wherein the first intermediate panel section has aside profile width less than or equal to a side profile width of thesecond intermediate panel section.
 4. The tonneau cover of claim 1,wherein a first flexible hinge attaches the first cover panel section tothe bulkhead panel, a second flexible hinge that attaches the firstintermediate panel section to the first cover panel section, a thirdflexible hinge that attaches the first intermediate panel section to thesecond panel section, a fourth flexible hinge that attaches the secondintermediate panel section to the second cover panel section, and afifth flexible hinge that attaches the second intermediate panel sectionto the third panel section.
 5. The tonneau cover of claim 1, wherein thefirst intermediate panel section has a side profile width that is notgreater than a side profile width of the second intermediate panelsection.
 6. The tonneau cover of claim 1, wherein at least one of thecover panel sections of the stack of cover panel sections has a sideprofile that is positioned non-parallel with at least one of anothercover panel section of the stack of cover panel sections.
 7. The tonneaucover of claim 1, wherein the stack of cover panel sections that ispivoted upright onto the bulkhead panel which supports the stack ofcover panel sections in an upright position is configured to not block acenter high mount stop lamp on the truck.
 8. The tonneau cover of claim1, wherein the bulkhead panel includes at least one tab, at least aportion of which is sized to engage at least a portion of the secondintermediate panel section to determine a location on the bulkhead panelthat supports the stack of cover panel sections in the upright position.9. The tonneau cover of claim 8, wherein the second intermediate panelsection includes at least one channel as the at least a portion of thesecond intermediate panel section to receive the at least a portion ofthe at least one tab.
 10. The tonneau cover of claim 8, wherein the atleast one tab on the bulkhead panel is a plurality of tabs.
 11. Thetonneau cover of claim 8, wherein the at least one tab on the bulkheadpanel has characteristics selected from the group consisting of at leastone of a detent, friction fit, and fastener.
 12. A tonneau cover for abed of a truck, the tonneau cover comprising: a bulkhead panel that isconfigured to secure to the truck; a plurality of cover panel sectionspivotably attached to each other; and an intermediate panel sectionpivotably attached to at least one of the cover panel sections of theplurality of cover panel sections; wherein the plurality of cover panelsections fold to form a stack of cover panel sections; wherein the stackof cover panel sections is pivoted upright onto the bulkhead panel whichsupports the stack of cover panel sections in an upright position;wherein the intermediate panel section sets upon the bulkhead panel whenthe stack of cover panel sections is pivoted upright onto the bulkheadpanel; and wherein the bulkhead panel includes at least one tab, atleast a portion of which is sized to engage at least a portion of thesecond intermediate panel section to determine a location on thebulkhead panel that supports the stack of cover panel sections in anupright position.
 13. The tonneau cover of claim 12, wherein the secondintermediate panel section includes at least one channel as the at leasta portion of the second intermediate panel section to receive the atleast a portion of the at least one tab.
 14. The tonneau cover of claim13, wherein the at least one tab on the bulkhead panel is a plurality oftabs.
 15. The tonneau cover of claim 13, wherein the at least one tab onthe bulkhead panel has characteristics selected from the groupconsisting of at least one of a detent, friction fit, and fastener. 16.The tonneau cover of claim 12, wherein the stack of cover panel sectionsform a generally triangularly-shaped side profile such that a bottomportion of the generally triangularly-shaped side profile of the stackof cover panel sections is wider than a top portion of the generallytriangularly-shaped side profile of the stack of cover panel sections.17. A tonneau cover for a bed of a truck, the tonneau cover comprising:a bulkhead panel that is secured to the truck; a first cover panelsection pivotably attached to the bulkhead panel; a second cover panelsection; a first intermediate panel section pivotably attached to thefirst cover panel section and the second panel section; a third coverpanel section; and a second intermediate panel section pivotablyattached to the second cover panel section and the third panel section;wherein the first cover panel section, the second cover panel section,and the third cover panel section fold to form a stack of cover panelsections; wherein the stack of cover panel sections is pivoted uprightonto the bulkhead panel which supports the stack of cover panel sectionsin an upright position; wherein the first intermediate panel section hasa side profile width less than a side profile width of the secondintermediate panel section; wherein the stack of cover panel sectionsform a generally triangularly-shaped side profile such that a bottomportion of the generally triangularly-shaped side profile of the stackof cover panel sections is wider than a top portion of the generallytriangularly-shaped side profile of the stack of cover panel sections.18. The tonneau cover of claim 17, wherein at least one of the coverpanel sections of the stack of cover panel sections has a side profilethat is positioned non-parallel with at least one other cover panelsections of the stack of cover panel sections.
 19. The tonneau cover ofclaim 17, wherein the bulkhead panel includes at least one tab, at leasta portion of which is sized to engage at least a portion of the secondintermediate panel section to determine a location on the bulkhead panelthat supports the stack of cover panel sections in the upright position.20. A tonneau cover for a bed of a truck, the tonneau cover comprising:a bulkhead panel that is secured to the truck; a first cover panelsection pivotably attached to the bulkhead panel; a second cover panelsection; a first intermediate panel section pivotably attached to thefirst cover panel section and the second panel section; a third coverpanel section; and a second intermediate panel section pivotablyattached to the second cover panel section and the third panel section;wherein the first cover panel section, the second cover panel section,and the third cover panel section fold to form a stack of cover panelsections; wherein the stack of cover panel sections is pivoted uprightonto the bulkhead panel which supports the stack of cover panel sectionsin an upright position; wherein the second intermediate panel sectionsets upon the bulkhead panel when the stack of cover panel sections ispivoted upright onto the bulkhead panel; and wherein the firstintermediate panel section has a side profile width less than or equalto a side profile width of the second intermediate panel section.